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TABLE OF CONTENTS
CHAPTER
1.1
1 - INTRODUCTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . ..*.....................
l-l
GENERAL . .. . .. .. .. .. ... .. .. .. .. ... .. .. .. .. .. ... . .. .. .. . .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. . .. .. . .. .. .. . .. .. .. .. . .. .. .. . . I-l
1-l
1.2
FACTORY SERVICE/ASSISTANCE *....................,.......,........................................
1.2.1
Technical Assistance, Service, and Repairs.. . ... . .. .. ... .. .. .. .. .. .. .. . .. .. .. . .. .. . .. .. .. .. . .. .. . 1-I
Parts and Service Related Business.. . .. .. . .. .. .. ... .. .. .. .. ... .. .. .. . .. .. . .. .. .. .. . .. .. . .. .. .. .. . .. . l-1
1.2.2
1.2.3
Technical Repair Assistance Hotline . .. . .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. . ... . . .. .. . .. .. ... . .. . ... . .. 1-i
CHAPTER
2 - THEORY OF OPERATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-l
MECHANICAL ASSEMBLIES ...............................................................................
2.1
2.1 .I
Drive Mechanism Assembly ..............................................................................
2.1.2
Pusher Block Assembly .....................................................................................
2.1.3
Syringe Holder Assembly ..................................................................................
2-l
2-1
2-2
2-2
2.2
ELECTRONIC CIRCUITS ......................................................................................
2.2.1
Microprocessor and Associated Circuits ...........................................................
2-3
2.2.1.1
2.2.1.2
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.2.8
2.2.9
2.2.10
2.2.11
2.2.12
2.2.13
2.2.14
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
Microprocessor ............................................................................................
Custom Integrated Circuit ............................................................................
RAM ..................................................................................................................
Program Cartridge (ROM) .................................................................................
Real Time Clock ................................................................................................
SYSOK and Latching Reset Circuit ...................................................................
Motor Drive Circuit ............................................................................................
Keypad ..............................................................................................................
LCD Panel .........................................................................................................
Audible Alarm ....................................................................................................
Printer Output ....................................................................................................
Power Supply ....................................................................................................
Charger Circuit ..................................................................................................
On/Off Circuit ....................................................................................................
Power Supply Circuit.. .......................................................................................
2-3
2-3
2-4
2-5
2-5
2-5
2-5
2-6
2-6
2-6
2-7
2-7
2-7
2-7
2-7
2-8
SENSING ELEMENTS AND CIRCUITS .. .. .. . .. ... .. .. . .. .. .. ... ...*...............*.*.....*.......... 2-8
Door Sensor . .. .. .. .. .. .. .. ... .. .. .. ... .. .. .. .. . .. .. . .. .. .. ... . .. . ... .. .. .. ... .. .. .. . .. .. . ...*..*................. 2-8
Lock Sensor . .. .. .. .. .. .. .. ... .. .. .. ... .. .. .. . .. .. .. . .. .. .. .. .. .. . ... .. .. .. ... .. .. .. . .. .. .. . .. .. . .. .. .. .. . .. .. .. . . 2-8
5 mL and End of Syringe Sensors . .. . .. .. . .. .. .. .. .. . ... .. .. .. ... .. .. .. . .. .. .. . .. .. . .. .. .. .. . .. .. .. . . 2-8
Occlusion Sensor .. .. .. .. .. ... .. .. .. .. .. .. ... . . .. .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. 2-9
Syringe Plunger Capture Sensor . .. . .. .. .. . .. .. ... .. . . ... .. .. .. ... .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. 2-9
Leadscrew Gear Sensor .. .. .. .. .. .. .. .. .. . .. .. . .. .. ... .. .. . ... .. .. .. .. .. .. .. .. .. . .. .. . .. .. .. . .. .. .. .. . .. .. 2-9
-I-
.
TABLE OF CONTENTS
CHAPTER
3.1
3.2
3.3
AND DAMAGE
CHECK . . . . . . . . . . . . . . . . . . . . 3-1
4 - FUNCTIONAL
5 - ROUTINE
MAINTENANCE
6 - TROUBLESHOOTING
6.1
GENERAL
6.2
6.2.1
6.2.2
6.2.3
6.2.4
TROUBLESHOOTING
.. . . .. .. .. . ... .. .. .. .. .. .. . .. ... .. .. . ... .. . ... .. .. .. .. ... .. .. .. .. .. .. ..*......................................
...........................................................................................
7 - DISASSEMBLY/ASSEMBLY
7.1
GENERAL
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
DISASSEMBLY
5-1
5-1
5-1
AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Board Exchange ................................................................................................
Tools and Equipment .........................................................................................
Troubleshooting Tips .........................................................................................
System Error Codes ..........................................................................................
CHAPTER
4-2
4-2
4-2
4-3
4-3
4-4
4-4
4-5
4-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-I
GENERAL ..............................................................................................................
CLEANING AND DISINFECTING ..........................................................................
LUBRICATION .......................................................................................................
CHAPTER
3-1
3-1
3-I
TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
POWER-UP ............................................................................................................
AlTENTlON
LIGHT ...............................................................................................
PUSHER BLOCK ...................................................................................................
SYRINGE HOLDER ...............................................................................................
OCCLUSION SENSING .........................................................................................
5 ML ALARM ..........................................................................................................
END OF SYRINGE ALARM ...................................................................................
FLOW RATES AND DELIVERY VOLUMES ..........................................................
AC POWER KIT (OPTIONAL) ...............................................................................
CHAPTER
5.1
5-2
5.3
INSPECTION
GENERAL ..............................................................................................................
INITIAL INSPECTION AND DAMAGE CHECK .....................................................
INSPECTIONS .......................................................................................................
CHAPTER
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.0
4.9
3 - INITIAL
PROCEDURES
6-1
6-I
6-l
6-2
6-2
6-6
. . . . . . . . . . . . . . . . . . . . . . 7-1
. . .. .. . .. .. .. .. .. .. .. . .. ... . ... . .. .. .. .. ... .. .. .. .. .. .. .. .. .. ... .. .. . .. . .. .. . .. .. . .. .. .. .. . .. .. .. . .. .. ....‘... 7-1
PROCEDURES
............................................................................
Syringe Cover ...................................................................................................
Rear Case Half Assembly .................................................................................
Battery Door Assembly ......................................................................................
Mechanism Assembly .......................................................................................
Front Switch Plate Assembly .............................................................................
7-1
7-2
7-3
7-4
7-5
7-6
TABLE OF CONTENTS
7.2.6
7.2.7
7.2.8
7.2.9
7.2.10
7.2.11
7.2.12
7.2.13
7.2.14
7.2.15
7.2.16
7.3
Patient Control Connector .................................................................................
MPU Circuit Board ............................................................................................
Case Cover Assembly .......................................................................................
Keypad ............................................................................................................
Syringe Holder ................................................................................................
Mechanism Circuit Board ................................................................................
5mL/EOS Switch Assembly .............................................................................
Motor Assembly ...............................................................................................
Syringe Block ..................................................................................................
Pusher Block Assembly ...................................................................................
Guide Rods .....................................................................................................
MECHANISM
REASSEMBLY
PROCEDURES
7-7
7-8
7-9
7-l 0
7-l 0
7-I 1
7-12
7-13
7-l 4
7-l 5
7-l 6
.. .. .. .. .. . .. ... .. .. .. .. .. .. .. . .. .. . .. .. .. .. . .. .. ... 7-17
7.4
SYRINGE BLOCK ALIGNMENT .........................................................................
7.4.1
Syringe Block Alignment .................................................................................
7.4.2
Limit Distance Calibration ...............................................................................
7.4.3
Syringe Block Adjustment ...............................................................................
7-19
7-l 9
7-I 9
7-l 9
.,,~......,.,..............,........................‘,.............................
7-20
7.5
5 MUEOS ADJUSTMENT
APPENDIX
A.1
GENERAL
APPENDIX
B.l
c.2.1
c.2.2
C.2.3
C.2.4
C.2.5
C.2.6
C.2.7
C.2.8
C.3
AND WIRING
DIAGRAMS
. . . . . . . . . . . . . . . . . . . . . ,... A-l
.. .. .. .. .. .. ... .. . .. .. ... .. .. .. .. .. .. ... .. . .. .. . .. .. .. . .. .. .. .. .. . .. ...*......................................
B - CIRCUIT
GENERAL
APPENDIX
C.l
C.2
A - SCHEMATICS
BOARD ASSEMBLY
DRAWINGS
. . . . . . . . . . . . . . . . . . ,... B-l
... . .. ... .. .. .. .. .. .. .. .. .. .. ...*................*.........................*....*.............................
C - REPAIR PARTS . . . . . . . . . . . . . . . . . ..~.....................‘........................
GENERAL ..............................................................................................................
ASSEMBLY PART LISTINGS ................................................................................
Syringe Cover ...................................................................................................
Rear Case Half ..................................................................................................
Labeling and Miscellaneous Hardware .............................................................
Front Case Half Parts ........................................................................................
Front Panel Assembly .......................................................................................
Mechanism Assembly .....................................................................................
EOS and 5 mL Switch Assembly .....................................................................
Syringe Block Assembly ..................................................................................
ALPHABETICAL
A-l
B-l
c-1
C-l
C-l
c-2
c-3
c-4
C-6
C-8
C-l 0
C-l 2
C-l 3
PARTS LIST . ... .. .. .. . .. .. .. . .. .. . .. .. .. .. .. .. . .. ... .. .. .. .. . ... . .. .. . .. .. .. .. . ... . .. .. c-14
.. .
- III -
TABLE OF CONTENTS
C.4
NUMERICAL
APPENDIX
D.l
PARTS LIST ..................................................................................
D - PRODUCT
GENERAL
UPDATES
........................................................
..............................................................................................................
REVISION
NOTICES ..........................................
C-l 7
D-l
D-l
APPENDIX
E - MANUAL
APPENDIX
F - REPAIR HISTORY . . . . . . .. ..*...................................................
F-l
APPENDIX
G - OPERATOR’S
G-l
MANUAL
- iv -
. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . ..‘..................
E-l
INTRODUCTION
Chapter I
1 .I GENERAL
This Service Manual has been developed to introduce the Biomedical Technician to the
PCA II Pump. This manual will provide a basic understanding of the internal workings of the
Pump, functional test procedures, complete assembly/disassembly instructions, troubleshooting, and parts list.
NOTE
Except for the procedures and part replacements included in this
document, no disassembly or repair should be attempted.
Baxter Healthcare provides a one-year limited warranty for each PCA II Pump. If a Pump
requires warranty service, call Baxter Healthcare for repair. Unauthorized repairing of a Pump
before the warranty has elapsed voids the warranty.
1.2 FACTORY SERVICE/ASSISTANCE
If factory service is desired, Pumps may be returned to Baxter Healthcare for repair.
To expedite repairs, call for a return authorization number before shipping any Pump to Baxter
Healthcare.
1.2.1 Technical Assistance, Service, and Repairs:
For technical assistance, parts ordering, and service return authorization, contact the Baxter
Healthcare Service Center:
1.2.2 Parts and Service Related Business:
I-800-343-0388
1.2.3 Technical Repair Assistance Hotline:
I-800-634-4602
1-l
Chapter
I
INTRODUCTION
THIS PAGE INTENTIONALLY
BLANK
-
1-2
THEORY OF OPERATION
/-
Chapter 2
2.1 MECHANICAL ASSEMBLIES
2.1. I
Drive Mechanism Assembly
The drive mechanism assembly is held between the Pump case halves and includes the
syringe holder (l), DC motor and gearbox (2), pusher block assembly (3), lead screw and
gear assembly (4), mechanism circuit board (5) and various sensing systems (described
later in this section under Sensing Elements and Circuits).
Fluid is delivered from the syringe by the action of the pusher block on the plunger of the
syringe. The pusher block is advanced by the action of the lead screw on the half-nut in the
pusher block assembly.The lead screw is turned by the DC motor through a gearbox integral
with the motor and a pair of pinion gears, one welded to the gearbox shaft with the other
attached to the lead screw. The Motor Drive Circuit provides control and delivery rate of the
fluids and is described later in this chapter.
Figure 2-I Drive Mechanism Assembly (out of case)
Chapter
THEORY OF OPERATION
2
2.1.2 Pusher Block Assembly
The pusher block assembly is captured between the stainless steel guide rods (1) of the
mechanism assembly. The pusher block extends through the opening between the case
halves where it engages the plunger of the syringe. Squeezing the release lever (2) against
the main support performs two functions. It allows the assembly to be moved freely up and
down the guide rod by mechanically de-coupling the half-nut from the lead screw (3), and it
disengages the pusher block assembly from the syringe plunger.
Figure 2-2 Pusher Block Assembly
2.1.3 Syringe Holder Assembly
The syringe holder assembly is connected to the drive assembly. It is designed to hold the
Baxter@Prefilled 50 cc, BD 60 cc, or Monoject’ 60 cc plastic syringes. Use of other syringes
will result in incorrect delivery rates.
1 Sherwood
2-2
THEORY OF OPERATION
-
Chapter 2
2.2 ELECTRONIC CIRCUITS
2.2.1 Microprocessor
and Associated Circuits
The MPU circuit board (1) is mounted on the inside of the front case cover on top of (and
covers) the LCD display board (2). External switches, sensors, and inputs are provided to the
MPU circuit board via direct connection and cabled input.
Figure 2-3 MPU Circuit Board Location
2.2.1.1
Microorocessor
The Motorola 68HCi 1A 1 microprocessor controls the functions of the Pump. It provides a
high performance single-chip microcontroller with Electronic Erasable Programmable Read
Only Memory (EEPROM), 16-bit timer, Serial Communication Interface (SCI), Serial Peripheral Interface (SPI), and an 8-bit Analog-to-Digital (A/D) converter. The 4 MHz crystal results
in a I MHz E clock at pin 5.
The microprocessor controls the motor through ports PA3-PA6. It communicates through a
buffer to the printer port.The MPU reads various analog signals through buffer U14. The bus
interface of the MPU to system RAM U3, program cartridge (ROM), real-time clock Ul, liquid
crystal display (LCD) and quadrature decoder IC U6 is through buffers U18, 19 and U20. The
custom IC U4 provides bus decoding and logic to interface the MPU to the keypad and sensors described later in this chapter.
2-3
Chapter
2
THEOWOF
OPERATION
At power up, the microprocessor conducts a number of Pump self-tests. Among these tests
are; a check of the watchdog circuit to ensure that the functional program code is intact; test
of RAM for full functionality; test of the A/D converter by sensing the voltage at PE3, pin 49
which ensures that the power supply is correct. If any of the self-tests fail, the microprocessor
will halt and the audio alarm will sound continuously.
2.2.1.2
Custom Integrated Circuit
The custom IC U4 performs several functions. It generates the System Reset, provides physical
memory mapping, provides additional digital I/O ports for the microprocessor and contains a
watchdog circuit that will reset the microprocessor if the software fails to continually write to it
at a predetermined time interval.
System Reset (RESET/, pin 43) can be asserted by several different sources. At power on,
the charge time of Cl 0 through R20 provides a period of delay where the system is held in
reset through U4 pin 3, this allows the power supply voltage to stabilize before running the
MPU. PWR-ERR/ is a signal that will cause a System Reset to occur if the over/under
detector circuit senses that the power supply voltage is either above 6.OV or below 4.55V.
Reset will also be asserted if the program cartridge is not installed or as previously described
if a watchdog time-out occurs. RESET/ resets the microprocessor (disabling its output ports,
including the motor drive signals), disables the motor through the SYSOK circuit, deselects all
peripheral ICs and disables the custom ICs output ports as well. RESET/ also causes the
buzzer to sound continuously acting through U2 and CR2.
Physical memory mapping is based on the address generated by the microprocessor and the
R/W signal. Additionally, READ/ and WRITE/ strobes are generated to operate the ROM,
RAM, and real time clock.
The digital I/O ports on the custom IC pass digital signals to and from the microprocessor.
Most inputs are protected from static discharge by IOOK ohm series resistors. INOO-03and
OUTOO-03are used to decode the front panel keypad in a matrix fashion. The mechanism
sensors EOS/, 5ML/, and OCCL (inputs IN1O-l 2) are used to trigger the End of Syringe, 5 mL
and Occlusion alarms respectively. IN13 is used to detect closure of the patient switch and is
debounced by RAI 3c and C6 as well as in software. OUT1 0 is used to activate the sensor for
the door through Q4. OUT1 1 activates the display and, via Q3 and inverter Tl , the electroluminescent backlighting. SYSOKCLK and OUT12 are part of the SYSOK circuit described
later in this chapter. OUT20 and OUT21 activate the front panel Attention and Power LEDs,
respectively.
The watchdog circuit is a safety feature designed to guard against loss of motor control in the
event that software does not execute properly. It compares the 32 Hz clock provided by Ui 2
to a write of a specific address by the microprocessor. If the two events are not properly
synchronized, a system reset is generated.
2-4
THEORY OF OPERATION
Chapter 2
2.2.2 RAM
8K bytes of system RAM are provided by U3 and an additional 256 bytes are located inside
the microprocessor. U3 is powered from VRAM and continues to store data even when the
Pump is turned off, and up to 20 minutes with the batteries removed. This allows for recalling
and printing patient information even after the Pump has been turned off.
2.2.3 Program Cartridge (ROM)
The Program Cartridge contains the software code that operates the Pump. It is accessed via
connector J15 on the MPU board. It has a capacity of 64K bytes. The custom IC allows
access to most locations not used by other devices.
2.2.4 Real Time Clock
The real-time clock Ul provides data and time information to the microprocessor. It is powered by VRAM and continues to operate even when the Pump is turned off, and up to 20
minutes with the batteries removed.
2.2.5 SYSOK and Latching Reset Circuit
The System OK (SYSOK) and latching reset circuit performs several functions. It provides
the SYSOK signal, a means to test the functionality of the watchdog circuit and a means to
latch the RESET/ signal. The System OK (SYSOK) circuit prevents the microprocessor from
driving the motor until several of the following events have taken place:
1) Power on reset has expired
2) The watchdog has been tested by allowing it to time out the first time the microprocessor
is started at power up.
Unless both of the above events have occurred the SYSOK flip flop UQa will not go high
signifying that the system has been properly initialized. The SYSOK signal UQa, pin 6 is
gated with MPOWER to form the PWM signal which is used to drive the motor. As long as
SYSOK is low, PWM is inhibited. Power On reset is used to initialize the circuit at power up.
The Power On reset signal is further delayed by R23/C25 and inverted by Ul 1 to form PWR-UP
PWR-UP keeps the SYSOK flip flops UQb and Ui 5 cleared until power on reset has expired.
.Thewatchdog test is performed by purposefully causing the software not to service the watchdog if WDOG-TST is low (its initialized state after power up). Before the watchdog times out
the microprocessor clocks UQ pin 9 high setting WDOG-TST high by manipulating OUT-12
and INSEL/. The watchdog will then time out resetting the microprocessor which then starts
again. On the second start sequence the software sees that WDOG-TST is high and services the watchdog in the normal fashion. OUT-1 2 and INSEU are manipulated again which
causes U15, pin 5 to clock high. This signifies that the watchdog test has successfully executed. Any additional resets at after this point will clock U15b thereby latching the RESET/
signal.
2-5
Chapter
2
THEORY OF OPERATION
2.2.6 Motor Drive Circuit
The microprocessor controls the motor through three output ports: MENABLE, MBRAKE,
and MPOWER. Primary motor motion feedback is provided by an encoder internal to the
motor powered by microprocessor port MENCOD and monitored by quadrature decoder U6.
Lead screw position feedback is provided through the REED input.
MENABLE is on (high) whenever the motor is active. Its primary function is to supply a
ground path to run the motor. It has a secondary function in that its absence can disable
operation of the motor in the event of the failure of the MPOWER signal or transistor.
MPOWER is a pulsatile signal which is AC coupled through C 17 and enabled by SYSOK
through U8a on the MPU board. Renamed PWM, it passes to the Mechanism board where it
controls the constant current driver transistor Q9. This in turn drives Ql 1, which provides
power to the motor. In addition, the motor power is controlled by the normally closed occlusion
switch SW1, which opens during an occlusion.
MBRAKE causes Ql 0 on the Mechanism board to short across the motor windings and halt
the motor between pulses. It also provides braking action during bolus and dose delivery for
better motor control.
The motor contains a 12 count quadrature encoder. Its outputs, ENCA and ENCB, are processed by the quadrature decoder U6 on the MPU board. The 15 kHz clock from U7, disabled
by CTRRST when the motor is not moving to reduce power consumption, sets the digital filter
frequency of U6. U6 contains a 12 bit counter that counts up or down depending on the
phasing of ENCA and ENCB, and is monitored by the microprocessor through the address/
data bus. The microprocessor periodically clears the counter via the ENCRST/ signal. The
motor drive transistors Q8, Q9, and Ql 1 are tested at power on and then periodically
while in operation to ensure that none are shorted. If this test fails, a system error alarm
results.
2.2.7 Keypad
The front panel keypad is decoded in a matrix fashion by the microprocessor via the custom
IC.
2.2.8 LCD Panel
The 64 x 84 dot matrix LCD panel is controlled by the microprocessor via the address / data
bus. To conserve battery power, it is blanked using the DISPLAY output of the custom IC.
DISPLAY also turns on Q3, which in turn powers voltage inverter Ti , which excites the electroluminescent lamp that backlights the LCD.
2-6
THEORY OF OPERATION
Chapter
2
2.2.9 Audible Alarm
The audible alarm is activated by either the AUDIO signal from microprocessor port pin 24 or
by the system reset signal RESET/ through U2 and CR2. This ensures the alarm will sound
if the watchdog times out.
2.2.10 Printer Output
The printer port uses the serial port within the microprocessor. All lines are buffered and have
transient absorbers with series resistors to provide protection from electrostatic discharge.
This serial port does not conform to RS-232, therefore, the Printer Adapter must be used if
printer capability is desired.
2.2. II Power Supply
The power supply consists of a switching regulator, a linear regulator and bypass FET, a
charger battery relay and an on/off circuit. Each of these subsystems are located on the
Mechanism Board (Figure 2-l).
2.2.12 Charger Circuit
--
A relay is used to switch between battery power and the AC wall charger power. When the AC
adapter is plugged in, the relay switches closing the normally open connections between the
AC adapter voltage and the power supply circuitry (VBATF). This also places a reverse
biased diode in series with the positive battery input. This reverse biased diode prevents
current from the AC charger from charging alkaline batteries. Charging current for NICAD
batteries is provided through F2, CR1 1 and R222 to the charge ring of the battery stick.
Reverse battery protection is provided by CR7 and Fi. If batteries are installed in reverse,
CR7 becomes forward biased and causes reverse current to open polyswitch Fi .
2.2.13 On/Off Circuit
Input voltage from the Charger circuit VBATTF is switched to the remainder of the power
supply via FET Qi. U205, a linear regulator, provides a constant supply for RAM backup
while the main power supply is switched off. C2 provides a short duration reservoir supply for
RAM backup while the batteries are being, changed. Ql is turned on when the On button is
pressed inside the syringe cover. This applies the battery voltage to the gate of Q6 which
provides a ground path for U2 turning it on. U2 provides a -5V signal to the source of Q13
turning it on which then turns on QI. The presence of 5V at the cathode of CR4 keeps Q6
turned on thereby keeping the power supply turned on. Pressing the OFF button applies 5V
to the gate of Q5 after a delay determined by RI 02/C9, which turns Q6 off. By reversing the
turn-on process this turns the power supply off. The RI 02/C9 delay allows the microprocessor some time to shut down in response to XIRQ/ output from U2 pin 8.
2-7
Chapter 2
THEORY OF OPERATION
2.2.14 Power Supply circuit
The switching regulator Ul is used to boost the input voltage when the battery voltage falls
below 5V When the batteries are fresh, power is supplied through diode CR1 . As the battery
voltage falls below SV, the switching regulator takes over to maintain voltage at 5V U202, a
linear regulator, is used to keep the power supply output voltage at 5V when the switching
regulator is not boosting voltage and the batteries are supplying more than 5V. FET Q201 is
used to bypass the linear regulator when the switching regulator is on, to minimize the voltage
drop when the linear regulator is not needed. Q201 can be turned on by either of two sources.
REG-BYP is a signal from the MPU which turns on Q201 through Q204. The A/D converter
within the MPU monitors the output of Ui via signal V-641 the software can then determine
when to switch in and out U202. The second way Q201 can be turned on is by voltage
detector U203. The AC adapter voltage CHG-MON is input to the voltage detector chip
through a voltage divider network R212/R213. If the voltage at U203 pin 3 goes above 1.3V
signifying that the AC adapter is in place the bypass FET Q201 is forced on. A second portion
of U203 is used to monitor the battery voltage VBATTF.This is done through another voltage
divider network R220/R221, and ensures that the power supply does not turn on automatically via Cl0 remaining charged and keeping Q6 on if the batteries are quickly removed and
reinstalled. A diode voting network selects between sources of VRAM. The two diodes CR1 0
and CR9 ensure that the higher of the two supplies are used.
2.3 SENSING ELEMENTS AND CIRCUITS
2.3.1 Door Sensor
The Pump senses that the door is closed by the proximity of a magnet imbedded in the door.
This is done using a Hall effect switch mounted in the front case half. The output, DOOR, is
read by the microprocessor at PE5, pin 46. To conserve battery power, the sensor is activated by the microprocessor via the HALLON/ signal only while it is being read.
2.3.2, Lock Sensor
The closure of the door lock on the front panel is sensed by a microswitch mounted to the
back of the front panel. The signal is read by the microprocessor at PE7, pin 50. A transient
absorber and series resistor are provided for protection from electrostatic discharge.
2.3.3 5 mL and End of Syringe Sensors
Two microswitches are mounted on a bracket attached to the mechanism assembly to sense
the location of the pusher block assembly.
2-8
THEORY OF OPERATION
Chapter 2
2.3.4 Occlusion Sensor
The syringe holder assembly attaches to the occlusion actuator block which is held in position
by a spring and two preload collars. When the force on the syringe holder due to pressure in
the fluid delivery system overcomes the actuator spring force, the occlusion actuator block
begins to move and actuates the occlusion switch SW1 located on the mechanism board.
The switch opens, removing power from the motor drive circuit and sending a signal OCCL to
the microprocessor via Q3 on the mechanism board. When the pressure in the fluid system
is released, the spring returns the actuator block to its normal position and the microswitch
resets.
2.3.5 Syringe Plunger Capture Sensor
A hall effect switch located within the pusher block main support is biased ‘on’ by a magnet
also located in the main support. If a syringe plunger is not captured under the pusher block
finger lever, then a magnet located in the lever biases the hall effect switch ‘off’. Correctly
capturing a syringe plunger flange keeps the magnet in the lever away from the hall effect
switch, allowing the switch to be biased ‘on’ in the main support. This information is passed to
the microprocessor through the PBLOCK/ signal and is read at PE4, pin 44. This bias scheme
ensures that the Pump will not operate if the sensor is not connected or if the connector or a
wire fails.
2.3.6 Lead Screw Gear Sensor
A magnet on the lead screw gear activates a reed switch mounted above it. The resulting
REED signal is read by the microprocessor at PA2, pin 32. The microprocessor continually
checks the motion detected by this sensor against the motion detected by the primary motor
encoder. If this does not agree, then a system error alarm occurs.
2-9
Chapter
2
THEORY OF OPERATION
THIS PAGE INTENTIONALLY
2-10
BLANK
INITIAL
INSPECTION
AND DAMAGE
CHECK
Chapter
3
3.1 GENERAL
This chapter contains the information necessary to perform an initial inspection and set up of
the PCA II Pump. A functional test is included in Chapter 4 to determine if operation is
satisfactory.
3.2 INITIAL INSPECTION AND DAMAGE CHECK
The PCA II Pump has been thoroughly tested and inspected at the factory prior to shipment
and has been found to comply to Baxter’s electrical and mechanical standards. However,
abusive handling during shipment may cause either visible or hidden damage. Follow the
instructions in this section before performing operational checks.
If any damage is observed in any of the following inspections, and this damage is related to
shipping, notify the carrier’s agent immediately Do not return the damaged equipment to the
factory without written authorization.
3.3 INSPECTIONS
1. Carefully inspect the shipping carton before opening it. Note any obvious damage caused
by mishandling and record any such damage.
2. The carton should contain the following:
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One PCA II Pump
One Locking Pole Clamp
One Patient Control Button
One Operators Manual and Quick Reference Guide
Two Keys
Two Screws to Optionally Mount Pole Clamp to Pump
3. Remove the Pump from the carton. Place the Pump on a flat surface and perform these
visual inspections:
A. Check the entire surface for chips, scratches, dents, or cracks
B. Check the front panel for damage to the membrane switch (such as peeling).
C. Peel off the plastic protective covering from the syringe cover.
D. Check the syringe cover for cracks and check to see that it locks properly.
E. Turn the Pump over and verify that the serial number matches that on the shipping
carton.
3-1
Chapter 3
INITIAL INSPECTION
AND DAMAGE
CHECK
4. Remove the pole clamp from the carton and check the following:
A. The lock operates smoothly.
B. When unlocked, the knob turns freely in both directions.
C. When locked, the knob turns clockwise but not counterclockwise
3-2
-
FUNCTIONAL
-
TESTS
Chapter
4
The Pump design includes extensive self-check procedures which continually monitor the
Pump’s operation. The user is usually unaware that these checks are being performed. If a
fault condition is detected, the appropriate visual and audible alarms are triggered. Pump
operation is halted until the error is corrected.
It is recommended that the following characteristics of the Pump be tested. Each of the tests
listed below are described in detail later in this chapter. Prior to beginning any test, ensure
batteries are installed properly (i.e. correct polarity).
Power-up - (4.1)
Attention Light - (4.2)
Pusher Block - (4.3)
Syringe Holder - (4.4)
Occlusion Sensing - (4.5)
5 mL Alarm - (4.6)
End of Syringe Alarm - (4.7)
Flow Rates and Delivery Volumes - (4.8)
AC Power Kit (Optional) - (4.9)
NOTE
Make sure that a cartridge is installed in the Pump before starting the
tests.
NOTE
The following instructions are for use with the Multi-Mode Cartridge (P/N
6464545) only! Please contact the Baxter Service Department if this
cartridge is not available.
NOTE
If a Pump fails the initial test, repeat the test. If the Pump still fails the
test, call a Baxter representative for a service authorization number and
the procedure for returning a Pump for repair.
NOTE
If using the optional AC Power Kit, all tests must be performed with the
power pack plugged into a 120V AC outlet.
4-1
Chapter
4
FUNCTIONAL
TESTS
4.1 POWER-UP
Press the On button. The audio alarm will beep and be followed by a self test message on the
display. If an error message appears, perform the following corrective action:
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Press the off button to turn the Pump off.
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Check to make sure the cartridge is properly seated in its slot.
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Press the On button.
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If a system error alarm appears, record the error number, (or, if the Pump beeps continuously with no message, turn the Pump OFF and repeat the test by turning the Pump ON
again).
If the failure recurs, the Pump requires service.
4.2 AlTENTlON
LIGHT
Push and turn the key to “Unlock” and open the syringe cover. The red light should flash
whenever the key is in the unlocked position, a prescription has been entered and is not
running, or the syringe cover is open.
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If a system error alarm appears, record the error number, turn the Pump OFF and repeat
the test by turning the Pump ON again.
If the failure recurs, the Pump requires service.
4.3 PUSHER BLOCK
Squeeze the release lever of the pusher block and check for free movement of the pusher
block over the complete travel. Release the lever and ensure that the pusher block assembly
reengages with the lead screw (should not move freely). The anti-siphon latch of the pusher
block captures the syringe plunger to prevent siphoning. Also perform the following to verify
correct operation:
1, Insert syringe in Pump, but do not connect pusher block to syringe plunger.
2. Press “Enter”.
3. The pusher block not connected message should appear.
4. Slide the release lever down until it snugly meets the top of the syringe plunger flange.
4-2
FUNCTIONAL
TESTS
Chapter
4
5. Release the lever to engage the anti-siphon latch under the syringe plunger flange.
6. Close and lock the cover then press “Clear”.
7. Enter and verify a prescription.
8. Press START. The Pump should begin running the entered prescription.
9. If a problem occurs, return the Pump for service.
4.4 SYRINGE HOLDER
Check the holding ability of the syringe holder. Ensure that a 60 cc plastic syringe (B-D
Plastipak* or Sherwood Monoject only) or a Baxter@50 cc prefilled syringe sits firmly in the
holder. The syringe barrel flange must be placed in the slot of the holder. If a problem occurs
perform the following:
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Make sure that a proper syringe is being used.
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If the failure can not be corrected, return the Pump for service.
4.5 OCCLUSION SENSING
The Occlusion Halt message appears on the screen, the red Attention light flashes, and the
alarm sounds. Perform the Occlusion sensing test as follows:
I. Push and turn the key to the UNLOCK position.
2. Open the syringe cover.
3. Press the On button.
4. Fill a syringe with 10 mL of water and attach a Baxter@tubing set to the end of a syringe.
5. Install the syringe and tubing set in the Pump and close the cover.
6. Press [3] to select the Continuous Infusion Mode.
7. Select mL.
8. Program a rate of 99 mL/hr and an amount of IO mL.
9. Press the START/STOP button.
2 B-D
4-3
Chapter
4
FUNCTIONAL
TESTS
IO. Fluid should begin flowing from the end of the tubing set.
11. Clamp the tubing set near the tip of the syringe.
12. Within 3 minutes the following should occur:
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the occlusion message appears on the display.
the red Attention light flashes, and
the alarm sounds.
13. Remove the clamp.
14.Continue to the 5 mL, alarm test.
4.6 5 ML ALARM
Check the operation of the alarm by following the procedure below:
1. Press the START button to resume the already programmed continuous infusion. If you
are not continuing a previous program, refer to paragraph 4.5 step l-9 for initial set up.
2. When there is approximately 4-6 mL remaining in the syringe, the following should occur:
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The 5 mL remaining message appears on the display
The red Attention light flashes, and
the alarm sounds.
3. Press the CLEAR button and continue to the End of syringe alarm test.
4.7 END OF SYRINGE ALARM
Check the operation of the alarm by following the procedure below:
1. This test is a continuation of the 5 mL left alarm of paragraph 4.6. When the syringe is
empty the following should occur:
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The end of Syringe message appears on the display,
The red Attention light flashes, and
The alarm sounds.
2. Ensure that the syringe contains 2 mL or less of fluid.
4-4
_
FUNCTIONAL
TESTS
Chapter
4
4.8 FLOW RATES AND DELIVERY VOLUMES
To check rates and volumes, Baxter Healthcare recommends the use of a distance gauge
calibrated in 0.001 inch increments. For details, refer to the Accuracy Test Kit, Catalog no.
6464460). If necessary, the following method of using a 10 mL, 0.05 mL/div burette and
stopwatch may be substituted.
I. Fill a 60 cc syringe with water and install it in the Pump.
2. Turn the Pump power ON.
3. Prime the system to eliminate all air from the fluid path.
4. Connect the burette to the tubing set.
5. Prime until water is at 0 mL level in the burette.
6. Close and LOCK the syringe cover.
7. Press [3] for continuous infusion mode.
8. Press [l] for mL.
9. Program the following:
a rate of 20 mL/hour
an amount of 5 mL
noKV0
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IO. Press the START/STOP button on the Pump and start the stopwatch simultaneously.
11. When the infusion is complete stop the timer. The time required should be 15 minutes 227
seconds (~3%). The actual volume delivered should be 5 mL +0.15 mL (?3%).
4.9 AC POWER KIT (OPTIONAL)
The display flashes “Battery Power” when the Pump is operating on rechargeable batteries.
Perform the following to verify that this occurs:
1. Disconnect the power pack from the Pump.
2. After a short delay, verify “Battery Power” is now flashing on the display.
3. If the display does not change, check to see that rechargeable batteries are being used
and that they are properly installed.
4. Reconnect the power pack and verify that the display no longer flashes “Battery Power”.
4-5
Chapter
4
FUNCTIONAL
TESTS
THIS PAGE INTENTIONALLY
4-6
BLANK
ROUTINE
MAINTENANCE
Chapter
5
5.1 General
The Pump is designed to provide reliable service with only minor routine maintenance. A
periodic functional inspection of the Pump should be made at least every six months to assure proper operation. The Pump should be cleaned and disinfected if necessary, according
to frequency of use and hospital protocol.
5-2 Cleaning and Disinfecting
The exterior surfaces may be cleaned using a cloth dampened with water or a mild detergent,
then wiped dry. A mild germicide may be used as a disinfectant. Vestal LPH or equivalent is
recommended
The PCA II Pump is not liquid proof and must not be immersed in liquid.
Avoid getting liquids inside the Pump or permanent damage to the Pump
may result. Do not use alcohol for cleaning. Sterilization by ETO, steam,
etc., should not be attempted.
5.3 Lubrication
The lead screw should be lubricated once every six months using Versilube3G-322L grease.
Using the nozzle applicator supplied with the grease, squeeze a small amount on the entire
length of the lead screw. Apply grease by carefully inserting the nozzle straight into the case
channel thereby spreading the rubber seal. Use care to avoid damaging the seal. Figure 51 displays the syringe mechanism removed from the Pump to illustrate lead screw location.
The assembly does not need to be removed to apply lubrication.
(ICAUTION
Use only the recommended lubricant. A substitute lubricant may cause
permanent damage.
3 Novaguard
5-1
Chapter
5
ROUTINE
MAINTENANCE
Figure 5-1 Syringe Mechanism
5-2
TROUBLESHOOTING
AND REPAIR
Chapter
6
6.1 GENERAL
Pumps under warranty must be returned to the factory for troubleshooting and repair. Unauthorized disassembly/repair will void your warranty. When a Pump is malfunctioning, perform
the following to see if Pump operation can be restored. Ensure that the:
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program cartridge is properly seated.
batteries are installed and not depleted.
batteries are installed correctly (proper polarity).
patient control switch is properly installed.
pusher block is properly engaged on the syringe.
If this does not restore the Pump to operation refer to the troubleshooting chart later in this
chapter.
(WARNING
There are no internal user repairable parts available. The Pump must
only be serviced by a trained biomedicalengineering technician or Baxter
Healthcare personnel.
6.2 TROUBLESHOOTING
The troubleshooting procedure and tables in this section are written for repair to the board
level. Except for those items listed, circuit board components are not available from Baxter
Healthcare. Refer to Chapter 7 for disassembly procedures and Appendix C for part information.
6.2.1 Board Exchange
A board exchange program is available for most circuit boards in the PCA II Pump. Baxter
Healthcare provides a refurbished board in exchange for a returned defective board. Boards
which are damaged through unauthorized rework, missing components, or improper maintenance will not be eligible for this program. Call for an authorization number prior to shipping
the defective board.
6-I
Chapter 6
TROUBLESHOOTING AND REPAIR
6.2.2 Tools and Equipment
The following list of tools are recommended for use in maintaining and troubleshooting the
PCA II Pump. The troubleshooting chart assumes that these tools or their equivalent are
available for use.
6 Volt Power Supply
Oscilloscope
Screwdriver (Cross point)
Wire Cutters
Needle nose Pliers
%6”
Open End Wrench
Digital Voltmeter
Soldering Iron
Loctite 414 Adhesive
ESD Protection Station
60 cc Syringe (B-D or Sherwood Monojet)
Tubing Set
10 mL, 0.05 mL/div burette with stand
Stopwatch or timer (minutes and seconds)
Non-vented luer lockcap or tubing set clamp.
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6.2.3 Troubleshooting Tips
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It is helpful to use a 6 Volt power supply when servicing a disassembled Pump. Ensure
that correct polarity is observed before applying power to the unit.
Operation of the syringe door can be simulated by shorting pins 1 and 3 of connection
JlO located on the MPU board. Shorting pins 1 and 3 simulates the door being closed.
Table 6-I Troubleshooting Chart
Symptom
No Power
Possible Cause
Solution
Dead Battery
Check/Replace batteries
Blown Fuse
Check/Replace fuse (located under
mounting plate).
Bad battery terminal connection Inspect/repair the battery terminals
or wires
and/or wires.
ON/OFF Switch
With the power disconnected,
check the continuity between pins
1 and 2 of Ji connector while depressing the “ON” button. If circuit
remains open, replace the ON/OFF
keypad.
Defective Mechanism Board
Replace the mechanism board.
6-2
TROUBLESHOOTING
AND REPAIR
Chapter
6
Symptom
Possible Cause
Solution
Unit will not turn off
ON/OFF Switch
With the power disconnected,
check the continuity between pins
3 and 4 of Jl connector while depressing the “ON” button. If circuit
remains open, replace the ON/OFF
keypad.
Defective Mechanism Board
Replace the mechanism board.
Buzzer
With Pump in alarm condition,
check the collector of Q7 on the
mechanism board with a scope for
a negative going pulse. If present,
replace buzzer.
Defective MPU Board
Check pin 12 of J2 on the mechanism board for a positive going
pulse. If missing, replace MPU
board.
Defective Mechanism Board
Replace the mechanism board.
Defective microswitch
Check/replace microswitch
Pusher block assembly
Check if the actuator on the pusher
block is intact and making contact
with the microswitch. Replace the
pusher block or align the switch
assembly as necessary.
Wiring and connectors
Inspect/repair as necessary.
Defective MPU board
Replace MPU board.
Defective microswitch
Check/replace microswitch
End block
Ensure that the actuator on the end
block is tripping the switch on the
mechanism board.
Defective Mechanism Board
Replace the mechanism board.
No audio alarm,
visual alarm OK
5 mL and/or EOS
alarm inoperative
Occlusion Alarm
inoperative
6-3
Chapter
6
TROUBLESHQOTING
AND REPAIR
Symptom
Possible Cause
Solution
LCD not working or
missing pixel(s)
Defective LCD
Replace LCD.
Defective MPU board
Replace MPU board.
Defective pusher block
If lead screw is turning and pusher
block is not moving, replace pusher
block.
Defective motor
Replace motor.
Defective mechanism board
Replace mechanism board
Defective MPU board
Replace MPU board.
Wear of pumping mechanism
Clean/lubricate lead screw and retest.
Worn half-nut
Inspect/replace pusher block assembly.
Unit will not infuse
Inaccurate flow rate
Display shows “UNL” Defective key switch
when syringe cover is
closed and locked.
Loose/missing cam
No input from front
panel keypad
Check/replace microswitch
Check lock cam for switch actuation, adjust as needed.
Defective/missing magnet
Replace syringe cover assembly.
Defective Hall effect sensor
Perform the syringe cover simulator procedure as described in section 6.2.3, if this procedure causes
the displayto indicate normally, replace the Hall effect sensor.
Defective keypad
With power removed, check keypad for continuity while pressing
the suspected key (refer to schematic for pinout). If circuit remains
open, replace keypad.
Defective MPU board
Replace MPU board.
6-4
TROUBLESHOOTING AND REPAIR
Chapter 6
NOTE
If an error code should appear, remove all power and restart the Pump.
A problem is indicated if the alarm persists. Due to the fact that error
codes shutdown the unit, it is difficult to troubleshoot without swapping
out suspected assemblies. As all error codes are software generated,
the software cartridge and the MPU board are always suspect. For a
complete explanation of the error codes refer to 6.2.4.
EIO, El 1, E14, E15,
E17, E39, E40, E50,
E51, E52, E53, E54,
E70, E71, E72, E80,
E81, E82, E83, E84,
E85, E86, E87, E88,
E90, E91, E92, E93,
E94, E95, E96, E97
Defective software cartridge
or MPU board.
Replace software cartridge or MPU
board.
E33, E34, E37
Defective/Misaligned Reed
Switch Assembly
Adjust/replace reed switch.
E60, E61, E62, E63
Defective mechanism board
Replace mechanism board.
E13, E64
Defective MPU board.
Replace MPU board.
E30, E31, E32
Defective motor
Replace motor
El2
Defective 5 mL switch
Adjust/Replace 5 mL switch.
El3
Defective/Missing magnet or
defective hall effect sensor.
Check Hall effect sensor as
described in section 6.2.3.
El6
Defective LED
Check/replace LED(s)
EOl -E09, El 8-E29,
E41-E49, E55-E59
E65-E69, E73-E79
NOT USED
6-5
Chapter
6
TROUl3LESHOOTlNG
AND REPAIR
6.2.4 System Error Codes
Below is a listing of all error codes that the PCA 11~
Pump can generate. Refer to the Troubleshooting Chart (Table 6-1) for corrective action should one of these alarms occur. This list is
provided for reference purposes only.
CODE
Description
EOI-E09
El0
El1
El2
El3
El4
El5
El6
El7
El 8-E29
E30
E31
E32
E33
E34
E35
E36
E37
E38
E39
E40
E41-E49
E50
E51
E52
E53
E54
E55-E59
E60
E61
E62
E63
E64
E65-69
E70
E71
E72
Not used
Keypad button held down more than 2 minutes
PCA button held down more than 2 minutes
EOS on without 5 mL switch activated
Illegal open door occurred
Analog to digital converter busy flag time-out
Display controller busy flag time-out
Voltage error during LED test
Unable to get stable reading from decoder
Not used
No motor encoder counts after several motor pulses
Motor pulse width below minimum
Motor pulse width above maximum
Lead screw comparison error, +25%
Lead screw comparison error, -25%
Too many motor counts received, +3%
Too few motor counts received, -3%
Lead screw counts received when motor should be stopped
Motor counts received when motor should be stopped
Motor drive circuit failure
Motor disable circuit failure
Not used
Clock comparison error
Bad data received from RTC chip
Real Time Clock chip is running too fast
Incorrect time data received from RTC chip
Unable to write data to RTC chip
Not used
Regulated voltage over upper limit
Regulated voltage below lower limit
Charge ring detect failure
Charge insertion detection failure
No detectable power source
Not used
OPTION register data verification error
MPU set to test mode
CONFIG register data verification error
6-6
TROUBLESHOOTING
AND REPAIR
CODE
Description
E73-E79
E80
E81
E82
E83
E84
E85
E86
E87
E88
E89
E90
E91
E92
E93
E94
E95
E96
E97
Not Used
Stack overflow
Invalid Rx entry step
Keypad buffer overflow
Unused screen error
Interrupts illegally disabled
Software COP error
System volume out of range
System rate out of range
Total injected has exceeded maximum
Not used
Screen index error
History checksum failure; History data corrupt
Rx data cannot be retrieved
A critical variable has been corrupted
Rx data checksum failure
Hardware revision does not match with its complement
An error detection variable has been corrupted
Motor save variable has been corrupted
6-7
Chapter
6
Chapter
6
TROUBLESHOOTING
AND REPAIR
THIS PAGE INTENTIONALLY
6-8
BLANK
DISASSEMBLY/ASSEMBLY
PROCEDURES
Chapter
7
7.1 GENERAL
This chapter contains a detailed description of the disassembly and assembly procedure for
the PCA II Pump. Contact Baxter Healthcare if you have any questions while servicing the
PCA II Pump.
[ICAUTION
When performing the procedures of this chapter, exercise extreme caution
during disassembly to protect the circuit boards from static discharge.
The inspection or repair station, all equipment, and personnel should be
properly grounded.
NOTE
During disassembly, note the orientation and routing of all cables and
connectors. Failure to do so may result in improper operation and/or
damage to the Pump upon reassembly.
NOTE
After a component is reassembled it must be aligned or adjusted per the
procedure listed as its retest requirement.
NOTE
All Pumps must pass the functional tests in chapter 4 after repair is
complete.
7.2 DISASSEMBLY PROCEDURES
The procedure to assemble a component is the reverse of the disassembly unless otherwise
noted. A complete assembly procedure for the mechanism assembly is provided in section
7.3.
Numbers in parenthesis refer to the numbered parts of the drawing associated with the procedure.
Prior to disassembly, remove all accessories, batteries, and the software cartridge.
7-1
Chapter
7
DISASSEMBLY/ASSEMBLY
PROCEDURES
7.2.1 Syfinge Cover
1. Unlock and open the syringe cover (1).
2. Remove the 4 pan head screws (2) and lock washers (3). Save the screws and lock
washers for use during assembly.
Figure 7-1 Syringe Cover Removal
7-2
DISASSEMBLY/ASSEMBLY
PROCEDURES
Chapter
7
-
7.2.2 Rear Case Half Assembly
1. Place the Pump face down on a fiat clean surface.
2. Remove the 5, screws (2) from the rear case half (1).
3. Gently pull the rear case half from the rest of the Pump assembly.
Figure 7-2 Rear Case Half
7-3
Chapter
7
DISASSEMBLY/ASSEMBLY
PROCEDURES
7.2.3 Battery Door Assembly
1. Remove the rear case half by following the procedure in section 7.2.2.
2. Disconnect the battery five pin connector J3 (1) from the mechanism board. Remove the red wire from the connector assembly
by lifting up the plastic retainer (a) and sliding the wire (b) out of
the connector.
3. Cut the tie wraps (2).
4. Remove the door keeper (3). The keeper is secured in place with Loctite 414 adhesive.
When replacing the keeper apply a thin coating of Loctite 414 adhesive to secure the
keeper in place.
5. Remove the battery door (4).
Figure 7-3 Battery Door Assembly Removal
DISASSEMBLY/ASSEMBLY
PROCEDURES
Chapter
7
7.2.4 Mechanism Assembly
1. Remove the rear case half assembly by following the procedure of section 7.2.2.
2. Locate and remove cable connection to J3 (1). J3 not shown in Figure 7-4, connection is
behind the microswitch. Disconnect cable from Jl (2). Connection identifications are also
noted on the board.
3. Partially lift the mechanism out of the case and disconnect the ribbon cable at J2 (3).
4. Lift the mechanism clear of the Pump case.
Figure 7-4 Mechanism Assembly (Removed From Case)
7-5
Chapter
7
DISASSEMBLY/ASSEMBLY
PROCEDURES
7.2.5 Front Switch Plate Assembly
1. Perform the following procedure before trying to remove the front switch plate assembly:
a) Remove the rear case half assembly using the procedure of section 7.2.2.
b) Remove the mechanism assembly using the procedures of section 7.2.4.
2. Remove the 6 screws (I) that secure the front case (2) half to the Pump housing. Note that
there are three different lengths of screws.
3. Partially remove the switch plate assembly. Disconnect the cables at Jl 0 (3) and J14 (4)
from the MPU. Carefully lift the Pump housing off of the front Switch Plate Assembly being
careful to thread the ribbon cable through the Pump housing opening.
Figure 7-6 Front Switch Plate Assembly
7-6
DISASSEMBLY/ASSEMBLY
PROCEDURES
Chapter
7
7.2.6 Patient Control Connector
1. Perform the following procedure before trying to remove the patient control connector:
a) Remove the rear case half assembly using the procedure of section 7.2.2.
b) Remove the mechanism assembly using the procedures of section 7.2.4.
c) Remove the front switch plate assembly using the procedures of section 7.25
2. During the front switch plate removal, JlO (2) was disconnected
from the MPU. JIO has the wires that go to the patient connector.
Pull this connector up through the Pump housing to disconnect
the patient connector wires. Remove the yellow and brown wires
from the connector assembly by lifting up the plastic retainer (a)
for each wire (b) and sliding the wire out of the connector.
3. Cut the tie wrap.
4. Loosen the nut that holds the patient connector (1) to the case. The connector is secured
in place with Loctite 414 adhesive. Gently pry the connector out of the case. When
replacing the connector apply a thin coating of Loctite 414 adhesive to secure it in place.
Figure 7-5 Patient Connector Assembly
Chapter
7
DlSASSEMBLY/A$SEMBLY
PROCEDURES
7.2.7 IUPU Circuit Board
1. Perform the following procedure before trying to remove the MPU board:
a) Remove the rear case half assembly using the procedure of section 7 2 2
b) Remove the mechanism assembly using the procedures of section 7.2.4. ’
c) Remove the front switch plate assembly using the procedures of section 7.2.5.
2. Remove the five screws (1) that hold the MPU (2) to the front panel assembly.
3. Disconnect the cables J9 (3) and Jl 1 (4) from the MPU.
4. Remove the MPU from the front panel.
5. To remove the display, turn the MPU over and remove the three screws that hold the
display to the MPU. Disconnect the cable at J13 and disconnect the ribbon cable from the
display
Figure 7- 6 MPU Circuit Board
7-0
DISASSEMBLY/ASSEMBLY
PROCEDURES
Chapter
7
7.2.8 Case Cover Assembly
1. Perform the following procedure before trying to remove the case cover components:
a) Remove the rear case half assembly using the procedure of section 7.2.2.
b) Remove the mechanism assembly using the procedures of section 7.2.4.
c) Remove the front switch plate assembly using the procedures of section 7.2.5.
d) Remove the MPU using the procedures of section 7.2.7.
2. To remove the latch microswitch (I), remove the two screws (2). The switch has a connector that attaches to J9.
3. To remove the latch assembly, remove the screw (3) and washer (4) that holds the latch
on the lock assembly.
4. Remove the latch and actuator (5) from the lock assembly.
5. Remove the nut (6) and washer (7) that secure the lock assembly to the front panel.
6. Lift bottom portion of the keypad.
7. Slip the lock assembly out the front of the panel.
Figure 7-7 Case Cover Assembly
7-9
Chapter 7
DlSASSElUBLY/ASSEMBLY PROCEDURES
7.2.9 Keypad
1. Perform the following procedure before trying to remove the case cover components:
a) Remove the rear case half assembly using the procedure of section 7.2.2.
b) Remove the mechanism assembly using the procedures of section 7.2.4.
c) Remove the front switch plate assembly using the procedures of section 7.25
d) Remove the MPU using the procedures of section 7.2.7.
NOTE
A keypad cannot be reused after it has been removed.
2. Turn the cover over with the keypad facing up. Lift the corner of the keypad and peel off
of the front panel.
7.2. IO Syringe Holder
1. Remove the syringe label (1). The label covers the securing screws and cannot be reused.
2. Remove the two screws (2) from the syringe holder.
3. Lift the syringe holder off of the mechanism assembly.
Figure 7-8 Syringe Holder
7 - 10
DISASSEMBLY/ASSEMBLY
-~
PROCEDURES
Chapter
7.2. II Mechanism Circuit Board
1. Perform the following procedure before trying to remove the mechanism circuit board:
a) Remove the rear case half assembly using the procedure of section 7.2.2
b) Remove the mechanism assembly using the procedures in section 7.2.4.
2. Remove the 3 screws (4) that hold the mechanism board (1) to the assembly.
3. Disconnect the 5 mUEOS microswitch wire connection at J6 (2).
4. Disconnect the pusher block cable at Ji 1 (3).
5. Slide the mechanism board off of the guide pin.
NOTE
When reassembling the mechanism board, ensure that the overpressure
microswitch (5) arm is aligned with the syringe block actuator.
Figure 7-9 Mechanism Circuit Board
7
Chapter 7
DISASSEMBLY/ASSEMBLY PROCEDURES
7.2.12 Sml/EOS Switch Assembly
1. Perform the following procedure before trying to remove the 5mL/EOS Switch assembly:
a) Remove the rear case half assembly using the procedure of section 7.2.2.
b) Remove the mechanism circuit board using the procedures of section 7.2.11.
2. Remove the 2 screws (2) that hold the microswitch assembly (1) to the mechanism assemblv.
Figure 7-10 5 mL/EOS Microswitch Assembly
3. To replace an individual switch, remove the two screws that hold the switch to the bracket
and desolder the wires from the switch.
4. After switch reassembly perform the switch adjustment in Section 7.3.
7 - 12
DISASSEMBLY/ASSEMBLY
PROCEDURES
Chapier
7.2.13 Motor Assembly
1. Perform the following procedure before trying to remove the motor assembly:
a) Remove the rear case half assembly using the procedure of section 7.2.2.
b) Remove the mechanism circuit board using the procedures of section 7.2.11.
2. Remove the 3 screws (1) that hold the motor assembly (3) to the motor pillow block.
2. Disconnect the motor cable from the mechanism board at J4 (2).
4. Remove the motor from the mechanism assembly.
Figure 7-11 Motor Assembly
7
-
13
7
Chapter
7
DISASSEMBLY/ASSEMBLY
PROCEDURES
7.2.14 Syringe Block
1, Perform the following procedure before trying to remove the syringe block assembly:
a) Remove the rear case half assembly using the procedure of section 7.2.2.
b) Remove the mechanism assembly using the procedures of section 7.2.4.
c) Remove the mechanism circuit board using the procedures of section 7.2.11.
2. Loosen the preload collar screw (4) and the Limit collar screw (1).
Use caution when removing the syringe block. The preload spring is
under tension and can come loose and become a hazard.
3. Slide the syringe block (3), collars (2)&(5), and preload spring (6) off of the guide rods.
Figure 7-12 Syringe Block Assembly
4. Refer to 7.3 for reassembly and alignment procedures.
7
-
14
DISASSEMBLY/ASSEMBLY
PROCEDURES
Chapter
7.2.15 Pusher Block Assembly
1. Perform the following procedure before trying to remove the pusher block assembly:
a) Remove the rear case half assembly using the procedure of section 7.2.2.
b) Remove the mechanism assembly using the procedures of section 7.2.4.
c) Remove the mechanism circuit board using the procedures of section 7.2.11.
d) Remove the 5 mL/EOS Switch Assembly using the procedures of section 7.2.12.
e) Remove the Syringe Block using the procedures of section 7.2.14.
2. Loosen the two screws (2) on the top of the middle pillow block (3).
Figure 7-13 Pusher Block Assembly Removal
3. Use a W’ open end wrench and nut driver to remove the threaded bushing (4) from the lead
screw.
4. Carefully slide the middle pillow block off of the
guide rods.
5. Remove the pusher block assembly (1) from the
guide rods.
-
6. Refer to 7.3 for reassembly and alignment procedures.
7 - 15
7
Chapter
7
DISASSEMBLY/ASSEMBLY
PROCEDURES
7.2.16 Guide Rods
1. Perform the following procedure before trying to remove the guide rods:
a) Remove the rear case half assembly using the procedure of section 7.2.2.
b) Remove the mechanism assembly using the procedures of section 7.2.4.
c) Remove the mechanism circuit board using the procedures of section 7.2.11.
d) Remove the 5 mL/EOS Switch Assembly using the procedures of section 7.2.12.
e) Remove the syringe block assembly using the procedures of section 7.2.14.
9 Remove the pusher block using the procedures of section 7.2.15.
2. Loosen the set screws (1) on the motor pillow block.
3. Gently tap the motor pillow block off of the guide rod.
Figure 7-14 Guide Rod Removal
3. Refer to 7.3 for reassembly and alignment procedures.
7 - 16
DISASSEMBLY/ASSEMBLY PROCEDURES
Chapter 7
7.3 MECHANISM REASSEMBLY PROCEDURE
Use this procedure to reassemble the mechanism from all of its base components.
1. Insert the guide rods (4) into the motor pillow block (2) so that the ends
of the guide rods are flush with the outside face of the motor pillow
block.
2. Tighten the set screws (1) in the motor pillow block that hold the guide
rods in place.
3. Slip the nylon washer (3) over the guide rod and put one drop of Loctite
414 adhesive on the washer to hold it in place.
4. Install lead screw assembly (5) through the motor pillow block assembly.
5. Slide the pusher block assembly (6) onto the guide rods and slip it up against the motor
pillow block.
Figure 7-I 5 Mechanism Reassembly
7
-
17
Chapter 7
DISASSEMBLY/ASSEMBLY PROCEDURES
6. Install the middle pillow block (7) onto the guide rods. Slide
it along the guide rods until it is flush with the end of the
lead screw. Insert a screwdriver into the middle pillow
block slot if it is difficult to slide along the guide rods.
7. Install the threaded bushing (8) & (9) loosely onto the lead
screw.
8. Use a nut driver to adjust the position of the middle
pillow block so that the distance from the inside
edge of the middle pillow blockto the outside edge
of the motor pillow block is 6.75”.
9. While holding the threaded bushing stationary
with the nut driver, use the open end wrench to
tighten the jam nut.
IO. Place the mechanism assembly into the rear case and ensure that the two pillow blocks fit
within the locators molded into the case.
11. Remove the assembly from the rear case.
12.Tighten the screws that secure the middle pillow block to the guide rods.
13. If not already attached, install the motor to the motor pillow block. Ensure that there is no
binding between the motor and lead screw gears. If necessary loosen and retighten the
motor screws to free up any binding.
14. Place the syringe block and limit collar onto the guide rods. Slide the preload spring XI of
the way onto the guide rod.
15. Using needle nose pliers, grasp the preload collar (leave space at the tip of the pliers for
the end of the spring).
16. Push the preload spring and preload collar completely onto the guide rod.
17. Adjust the syringe block as outlined in section 4.4.
7
-
18
DISASSEMBLY/ASSEMBLY
PROCEDURES
Chapter
7
7.4 SYRINGE BLOCKALIGNMENT
7.4.1 Syringe Block Alignment
1. insert a 0.030” gauge between the syringe
block (1) and the outside surface of the
threaded bushing (2).
2. Tighten the preload collar cap screw (3).
3. Verify that there is still 0.030” between the syringe block and the threaded bushing.
4. Bend the switch arm (5) until it just touches the
syringe block actuator (6).
// I/
7.4.2 Limit Distance Calibration
1. Insert a 0.038” gauge between the limit collar
(4) and the syringe block (1).
2. Slide the limit collar against the gauge and
tighten the limit collar cap screw.
3. Verify the 0.038” distance between the limit
collar and the syringe block.
7.4.3 Syringe Block Adjustment
1. Holding the mechanism
microswitch.
assembly firmly, pull back the syringe block toward the occlusion
2. Install a 0.014” gauge between the preload collar and the syringe block, then release the
syringe block.
3. Use an ohmmeter to measure the resistance between the two outside terminals of the
occlusion microswitch.
4. Check the resistance for a “closed’ condition. This is the normal operating position.
5. If the circuit reads “open”, bend the switch arm (5) (using needle nose pliers) slightly away
from the syringe block until a “closed” circuit is obtained.
6. Remove the 0.014” gauge and install a 0.023” gauge in its place.
7 - 19
Chapter
7
DISASSEMBLY/ASSEMBLY
PROCEDURES
7. Use an ohmmeter to measure the resistance between the two outside terminals
occlusion microswitch.
8. Check the resistance reading for an “open” condition.
position.
This is the occlusion
of the
activation
9. If the circuit reads “closed”, bend the switch arm (using needle nose pliers) slightly tighter
to the syringe block actuator until an “open” reading is obtained.
IO. Repeat this procedure from step one until no further adjustments are required.
7.5 5 ML/EOS ADJUSTMENTS
This procedure outlines the steps necessary to check and adjust the 5mL and EOS alarms.
For assembled Pumps, the unit may be set up to run in the basal mode and this test performed
using the 5 mL and EOS alarm signals as an indication of switch activation.
1. Adjust the plunger of a 60 cc syringe so that it lines up with the 8 mL division and install it
in the Pump. Ensure that the syringe flange is against the syringe holder.
2. Pull up on the pusher block release lever and SLOWLY move the pusher block toward the
5 mL switch.
3. Stop as soon as the 5 mL switch is activated. This can be detected through the audible
click of the switch or by monitoring the switch with an ohmmeter.
4. Verify the syringe reads 4 to 6 mL remaining. If it does not, complete
make adjustments as outlined in steps 8 or 9 below.
EOS testing and
5. Pull up on the pusher block release lever and SLOWLY move the pusher block toward the
ECS switch.
6. Stop as soon as the EOS switch is activated. This can be detected through the audible
click of the switch or by monitoring the switch with an ohmmeter.
7. Verify that the syringe reads 2 mL or less. If it does not, make adjustments
step 8 or 9 below.
as outlined in
8. If the switch activated too soon, loosen the two mounting screws that hold the assembly to
the mechanism assembly and slide the switch assembly toward the middle pillow block.
9. If the switch activated too late, loosen the two mounting screws that hold the assembly to
the mechanism assembly and slide the switch assembly away from the middle pillow block.
10. Repeat this procedure until no further adjustments
7 - 20
are needed.
SCHEMATICS
AND WIRING DIAGRAMS
Appendix
A
A.1 GENERAL
This appendix contains all of the schematic and wiring diagrams for the PCA II Pump. A table
of contents for this section is shown below:
Drawing Number
6464893
6464978
Description
SCHEMATIC, PCA II PUMP, MECHANISM BOARD
SCHEMATIC, PCA II PUMP, MPU BOARD
A-l
CIRCUIT
BOARD ASSEMBLY
DRAWINGS
Appendix
B
B.1 GENERAL
This appendix contains the circuit board assembly drawings for the PCA II Pump. A table of
contents for this section is shown below:
Drawing Number
6464895
6464980
Description
ASSY, PCB MECHANISM PCA II PUMP
ASSY, PCB Al MPU FINAL PCA II PUMP
B-l
REPAIR PARTS
Appendix
C
C.1 GENERAL
This appendix contains a part listing of the components of the PCA II Pump. There are three
part list types contained in this appendix, by major component, alphabetical, and numerical.
The numerical and alphabetical lists are cross referenced to the assembly specific parts list
by figure and index number.
C.2 ASSEMBLY
PART LISTINGS
This section contains a part listing by major assembly. A listing of the major assemblies is
shown below:
l
l
l
l
l
l
l
l
Syringe Cover
Rear Case Half
Labeling and Miscellaneous Hardware
Front Case Half
Front Panel Assembly
Mechanism Assembly
EOS and 5 mL switch assembly
Syringe Block Assembly
C-l
Appendix
C
REPAIR PARTS
C.2. I Syringe Cover
Table C-l Syringe Cover Parts
Figure
ID Number
1
2
3
Part Description
Syringe Cover Assembly
#4-40 x E’ Pan Head Screws
#4 Split Lock Washers
Figure C-l Syringe Cover Parts
Baxter Part
Number
Quantity per
Assembly
6464611RP
5101174
5110048
1
4
4
REPAIR PARTS
Appendix
C
C.2.2 Rear Case Half
Table C-2 Rear, Case Half Parts
Figure
ID Number
4
5
6
7
a
9
Part Description
Rear Case Assembly Complete
(Includes items 5-I 0, 12-l 6)
Tape Foam Neoprene
Polyurethane Seal
YG Sponge Neoprene Tape
Polarity Label
Battery Door Retainer
Figure C-2 Rear Case Half Parts
Baxter Part
Number
Quantity per
Assembly
6464939RP
1
5020174
6461434
5020190
5020169
6464624
1
1
1
1
1
Appendix
C
REPAIR PARTS
C.2.3 Labeling and Miscellaneous Hardware
Table C-3 Labeling and Miscellaneous Hardware
Figure
ID Number
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Part Description
Rear Label
#4-40 xl Y,” Pan Head Screws
Mounting Plate
#4-40 x %” Self Tapping Screw
Lockwasher
Fuse Window Label
Fuse Wlndow
Fuse, SOAMP,125 V
Support Disc
#4-40 x Y,” Self Tapping Screw
Syringe Loading Label
Syringe Flange Label
Syringe Holder Assembly
Syringe Warning Label
c-4
Baxter Part
Number
6464198
5101179
6461021
5101014
5140008
6464806
6464807
5146895
6464665
5137039
6464647
6464445
6461431
6461138A
Quantity per
Assembly
1
5
1
4
4
1
1
1
1
2
1
1
1
1
Appendix
C
REPAIR PARTS
C.2.4 Front Case Half Parts
Table C-4 Front Case Half Parts
Figure
ID Number
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Part Description
Front Case Assembly Complete
(includes Items 25, 26, 28-30, 37-40)
Polyurethane Seal
Tape, Foam Neoprene
Battery Spring Assembly
Printer Label
Cable Tie
Battery Door Keeper
Battery Door Assembly
Assembly Printer Connector
Dust Cover
Power Pack Connector Assembly
Contact, Charge Ring
Patient Control Connector Assembly
Magnetic Pin
ON/OFF Keypad
Warning Label
Cartridge Guide
C-6
Baxter Part
Number
Quantity per
Assembly
6464940RP
1
6461434
5020174
6464833RP
6464695
5113821
6464625
6464943RP
6464683RP
5146808
6464814RP
6464799
6464942RP
6464558
6464598
6464681
6464549
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
Appendix
C
REPAIR PARTS
C.2.5 Front Panel Assembly
Table C-4 Front Panel Assembly
Figure
ID Number
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
Part Description
MPU Board
4-40 x Y,” Self Tapping Screw
4-40 x 3/16” Pan Head Screw
Red LED
Green LED
#2-56 x 36” Pan Head Screw
Keyswitch Assembly
Cam Lock Lever
Syringe Cover Lock
Extension Lock Lever
Stand Off
LCD Window
LCD Module Assembly
Keypad
Case Front Cover
C-8
Baxter Part
Number
Quantity per
Assembly
6464980
5101167
5101104
010600008
010600007
5101165
6464572RP
6464515
6464678
6464514
5125113
646498 1
6464880RP
6464195
6464633
1
4
6
1
1
3
1
1
1
1
3
1
1
1
1
Appendix
C
REPAIR PARTS
C.2.6 Mechanism Assembly
Table C-5 Mechanism Assembly Parts
Figure
ID Number
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
Part Description
#4-40 x X3”Set Screw
Motor Pillow Block
Nylon Washer
Pusher Block Assembly (with sensor)
5 mL/EOS Switch Assembly (Refer to C.2.7)
#4 Split Lock Washer
#4-40 x Y,” Pan Head Screw
#4-40 x Y,” Pan Head Screw
Guide Rod
Flange Bearing
Threaded Bushing
Middle Pillow Block
Occlusion Switch
Roll Pin
Buzzer
Mechanism Board
Motor
#2 Internal Tooth Lock Washer
Reed Switch Assembly
M2 x 6MM Pan Head Screw
Lead Screw Assembly
c - 10
Baxter Part
Number
Quantity per
Assembly
5115054
6464627
5014035
6464934RP
2
1
1
1
1
2
5
5
1
1
1
1
1
1
1
1
1
2
1
2
1
5140008
5101061
5101166
6461424
5011037
6461110
6464628
5146626
5107011
5146778
6464895
5123286
5141009
6464621RP
5101164
6464623RP
Appendix
C
REPAIR PARTS
C.2.7 EOS and 5 mL Switch Assembly
Table C-7 EOS and 5 mL Switch Assembly Parts
Figure
ID Number
77
78
79
80
81
82
83
84
85
Part Description
#2-56 x y2’ Pan Head Screw
#2 Internal Tooth Lock Washer
EOS (Microswitch) Bracket
EOS Switch Insulator
EOS Microswitch
#2-56 Hex Nut
4 Position Male Connector
Cable Tie
5 mL Microswitch
Baxter Part
Number
Quantity per
Assembly
5101116
5143011
6464655
6464599
5112081
5135001
010135043
5113821
021000021
4
8
1
1
1
4
1
1
1
Figure C-7 EOS and 5 mL Switch Assembly Parts
REPAIR PARTS
Appendix
C
C.2.8 Syringe Block Assembly
Table C-8 Syringe Block Assembly Parts
Figure
ID Number
86
87
88
89
Part Description
#4-40 x W’ Pan Head Screw
Limit Collar
Syringe Block
Preload Spring
Baxter Part
Number
5101014
6461321
6465169
5009080
Figure C-8 Syringe Block Assembly Parts
c - 13
Quantity per
Assembly
2
2
1
1
Appendix
C
REPAIR PARTS
C.3 APLPHABETICAL PARTS LIST
Descripition
#2 Internal Tooth Lock Washer
#2-56 x i/2” Pan Head Screw
#2-56 x 7/X” Pan Head Screw
#2-56 Hex Nut
#4 Split Lock Washer
#4-40 x 3/8” Pan Head Screw
#4-40 x l/4” Pan Head Screw
#4-40 x 3/l 6” Pan Head Screw
#4-40 x 1-l/4” Pan Head Screw
#4-40 x l/8” Set Screw
#4-40 x l/4” Self Tapping Screw
#4-40 x 3/8” Self Tapping Screw
#4-40 x l/2” Self Tapping Screw
1/I 6” Sponge Neoprene Tape
4 Position Male Connector
5 mL Microswitch
Assembly Printer Connector
Battery Door Assembly
Battery Door Keeper
Battery Door Retainer
Battery Spring Assembly
Buzzer
Cable Tie
Cam Lock Lever
Cartridge Guide
Case Front Cover
Contact, Charge Ring
Dust Cover
EOS Bracket
EOS Microswitch
EOS Switch Insulator
Extension Lock Lever
Flange Bearing
Front Case Assembly
Fuse, 6/1OA, 125 V
Fuse Window
Fuse Window Label
Green LED
Guide Rod
Baxter Part
Number
Figure
Number
Index
Number
Unit
Qty
5141009
5101116
5101165
5135001
5140008
5101014
5101174
5101104
5101179
5115054
5101167
5101014
5137039
5020190
010135043
021000021
6464683RP
6464943RP
6464625
6464624
6464833RP
5146778
5113821
6464515
6464549
6464633
6464799
5146808
6464655
5112081
6464599
6464514
5011037
6464940RP
5146895
6464807
6464806
010600007
6461424
REF
C-7
C-5
c-7
FIEF
REF
REF
c-5
c-3
C-6
C-5
c-3
c-3
C-2
c-7
c-4
C-4
C-4
C-4
C-2
C-4
C-6
REF
C-5
C-4
C-5
C-4
C-7
C-7
C-7
C-7
C-5
C-6
C-4
C-3
C-3
C-3
C-5
C-6
REF
76
46
82
REF
REF
REF
43
11
56
42
13
19
7
83
85
32
37
36
9
27
70
REF
48
41
55
35
33
79
81
80
50
65
24
17
16
15
45
64
10
2
3
4
5
4
14
6
5
2
4
4
2
1
1
1
1
1
1
I
I
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
c - 14
REPAIR PARTS
C.3 APLPHABETICAL
Appendix
PARTS LIST (CONTINUED)
Descripition
Baxter Part
Number
Figure
Number
index
Number
Unit
Qty
Keypad
Keyswitch Assembly
LCD Module Assembly
LCD Window
Lead Screw Assembly
Limit Collar
Lock Washer
M2 x 6MM Pan Head Screw
Magnetic Pin
Mechanism Board
Middle Pillow Block
Motor
Motor Pillow Block
Mounting Plate
MPU Board
Nylon Washer
Occlusion Switch
On/Off Keypad
Patient Control Connector Assembly
Polarity Label
Polyurethane Seal
Power Pack Connector Assembly
Preload Spring
Printer Label
Pusher Block Assembly (with sensor)
Rear Case Assembly Complete
Rear Label
Red LED
Reed Switch Assembly
Roll Pin
Stand Off
Support Disc
Syringe Block
Syringe Cover Assembly
Syringe Cover Lock
Syringe Flange Label
Syringe Holder Assembly
Syringe Loading Label
Syringe Warning Label
6464195
6464572RP
6464880RP
6464981
6464623RP
6461321
5140008
5101164
6464558
6464895
6464628
5123286
6464627
6461021
6464980
5014035
5146626
6464598
6464942RP
5020169
6461434
6464814RP
5009080
6464695
6464934RP
6464939RP
6464198
010600008
6464621RP
5107011
5125113
6464665
6465169
6464611RP
6464678
6464445
6461431
6464647
6461138A
C-5
C-5
c-5
c-4
C-6
C-8
C-3
C-6
C-4
C-6
C-6
C-6
C-5
c-3
C-5
C-6
C-6
C-4
C-4
C-2
REF
C-4
C-8
C-4
C-6
C-2
C-3
c-5
C-6
C-6
c-5
C-3
C-8
C-l
C-5
C-3
c-3
C-3
C-3
44
47
53
52
76
87
14
75
38
71
67
72
57
12
41
58
68
39
31
8
REF
34
89
29
59
4
10
44
74
69
51
18
88
1
49
21
22
20
23
1
1
1
1
1
1
4
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
c - 15
C
Appendix C
REPAIR PARTS
C.3 APLPHABETICAL PARTS LIST (CONTINUED)
Descripition
Baxter Part
Number
Figure
Number
Index
Number
Unit
Qty
5020174
6461110
6464681
REF
C-6
c-4
FIEF
66
40
AR
1
1
Tape Foam Neoprene
Threaded Bushing
Warning Label
C - 16
REPAIR PARTS
Appendix
C.4 NUMERICAL PARTS LIST
Index Unit
Figure
Number Number Qty
Baxter Part
Number
Descripition
5009080
5011037
5014035
5020169
5020174
5020190
5101014
5101014
5101104
5101116
5101164
5101165
5101167
5101174
5101179
5107011
5112081
5115054
5123286
5125113
5135001
5137039
5140008
5141009
5113821
5146626
5146778
5146808
5146895
6461021
6461110
6461138A
6461321
6461424
6461431
6461434
6464195
6464198
6464445
Preload Spring
Flange Bearing
Nylon Washer
Polarity Label
Tape Foam Neoprene
1/I 6” Sponge Neoprene Tape
#4-40 x 3/8” Pan Head Screw
#4-40 x 3/8” Self Tapping Screw
#4-40 x 3/l 6” Pan Head Screw
#2-56 x l/2” Pan Head Screw
M2 x 6MM Pan Head Screw
#2-56 x 7/l 6” Pan Head Screw
#4-40 x l/4” Self Tapping Screw
##4-40x l/4” Pan Head Screw
#4-40 x I -l/4” Pan Head Screw
Roll Pin
EOS Microswitch
#4-40 x l/8” Set Screw
Motor
Stand Off
#2-56 Hex Nut
#4-40 x l/2” Self Tapping Screw
#4 Split Lock Washer
#2 Internal Tooth Lock Washer
Cable Tie
Occlusion Switch
Buzzer
Dust Cover
Fuse, 6/l OA, 125 V
Mounting Plate
Threaded Bushing
Syringe Warning Label
Limit Collar
Guide Rod
Syringe Holder Assembly
Polyurethane Seal
Keypad
Rear Label
Syringe Flange Label
c - 17
C-8
C-6
C-6
c-2
REF
c-2
REF
c-3
C-5
c-7
C-6
C-5
C-5
REF
c-3
C-6
C-7
C-6
C-6
c-5
C-7
c-3
REF
REF
REF
C-6
C-6
c-7
c-3
c-3
C-6
C-3
C-8
C-6
c-3
REF
c-5
c-3
c-3
89
65
58
8
REF
7
REF
13
43
77
75
46
42
REF
11
69
81
56
72
51
82
19
REF
REF
REF
68
70
33
17
12
66
23
87
64
22
REF
54
10
21
1
1
1
1
AR
1
4
4
6
2
2
2
5
14
5
1
1
1
1
3
4
2
5
10
2
1
1
2
1
1
1
1
1
1
1
2
1
1
1
C
REPAIR PARTS
Appendix C
C.4 NUMERICAL
PARTS LIST (CONTINUED)
Baxter Part
Number
Descripition
Figure Index Unit
Number Number Qty
6464514
6464515
6464549
6464558
6464572RP
6464598
6464599
6464611RP
6464621RP
6464623RP
6464624
6464625
6464627
6464628
6464633
6464647
6464655
6464665
6464678
6464681
6464683RP
6464695
6464799
6464806
6464807
6464833RP
6464880RP
6464895
6464934RP
6464939RP
6464940RP
6464942RP
6464943RP
6464980
6464981
6465169
010135043
Extension Lock Lever
Cam Lock Lever
Cartridge Guide
Magnetic Pin
Keyswitch Assembly
On/Off Keypad
EOS Switch Insulator
Syringe Cover Assembly
Reed Switch Assembly
Lead Screw Assembly
Battery Door Retainer
Battery Door Keeper
Motor Pillow Block
Middle Pillow Block
Case Front Cover
Syringe Loading Label
EOS Bracket
Support Disc
Syringe Cover Lock
Warning Label
Assembly Printer Connector
Printer Label
Contact, Charge Ring
Fuse Window Label
Fuse Window
Battery Spring Assembly
LCD Module Assembly
Mechanism Board
Pusher Block Assembly (with sensor)
Rear Case Assembly Complete
Front Case Assembly
Patient Control Connector Assembly
Battery Door Assembly
MPU Board
LCD Window
Syringe Block
4 Position Male Connector
C - 18
c-5
C-5
c-4
C-4
c-5
c-4
C-7
C-l
C-6
C-6
c-2
C-4
c-5
C-6
c-5
c-3
c-7
C-3
c-5
c-4
C-4
c-4
c-4
c-3
C-3
C-4
c-5
C-6
C-6
c-2
C-4
c-4
c-4
c-5
C-4
C-8
C-7
50
48
41
38
47
39
80
1
74
76
9
36
57
67
55
20
79
18
49
40
32
29
35
15
16
27
53
71
59
4
24
31
37
41
52
88
83
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Appendix
REPAIR PARTS
C
C.4 NUMERICAL PARTS LIST (CONTINUED)
Baxter Part
Number
Descripition
010600007
010600008
Green LED
Red LED
5 mL Microswitch
021000021
Figure Index Unit
Number Number Qty
c-5
c-5
C-7
c - 19
45
44
85
1
1
1
Appendix
C
REPAIR PARTS
c - 20
PRODUCT
UPDATES
Appendix
D
D.l GENERAL
This appendix describes major updates to the PCA II Pump. The updates are listed by serial
number and/or hardware revision number of when the change occurred. In many instances
a different part number is assigned for compatibility reasons. To ensure proper fit and operation of parts, make sure that you check all updates that may apply to a particular serial
number.
D-l
Appendix
D
PRODUCT
UPDATES
-
D-2
PRODUCT
UPDATES
Appendix
D
PRODUCT UPDATE 1
Pumps Affected
All units labeled as Hardware Revision 4.4 or above.
Update Description
Changed circuitry on the MPU and Mechanism circuit boards. Changed configuration of the
buzzer assembly.
Differences
The buzzer is removed from the MPU circuit board and is now located on the front case half
assembly. Pumps of this configuration can be identified by a Hardware Revision level of 4.4
or above. Revised schematics and circuit board assembly drawings are included as part of
this update.
Part Changes
Description
MPU Circuit Board
Mechanism Circuit Board
Buzzer Assembly
Cable Assembly
Front Case W/Buzzer Assembly
Fiaure Number
C-5
C-6
C-6
N/A
C-4
D-3
Index Number
41
71
70
N/A
24
New Part Number
6470124
6470120
6464094RP
6464091RP
6464089RP
Appendix
D
PRODUCT
UPDATES
The schematics and assembly drawings that follow are part of Product Update 1. A table of
contents for this section is shown below:
Drawing Number
6470119
6470128
6470120
6470124
Description
SCHEMATIC, PCA II PUMP, MECHANISM BOARD, ESD
SCHEMATIC, PCA II PUMP, MPU BOARD, ESD
ASSY, PC9 MECHANISM ESD PCA II
ASSY, PC9 Al MPU ESD FINAL PCA II
D-4
MANUAL REVISION NOTICES
Appendix E
Revision
Date
General Description of Changes
0
11191
NEW DOCUMENT RELEASE
1
6/93
Circuit Redesign
2
2/94
Division Logo Change
3
l/95
Updated to include Assembly/Disassembly, Troubleshooting,
and Parts List. Updated to include Hardware Revision 4.4
(Product Update APPDI)
E-l
Appendix
E
MANUAL
REVISION
E-2
NOTICES
REPAIR HISTORY
F-l
Appendix
F
Appendix
F
REPAIR HISTORY
-
F-2